Armor making combines sheet metal work, riveting, and articulation. This campaign covers armor types, plate forming, riveting, articulation, and padding.
Chapter 1: Armor Types
Type
Material
Protection
Weight
Mobility
Difficulty
Padded (gambeson)
Linen/wool layers
Low-moderate
5-10 lbs
Excellent
Low
Mail (chainmail)
Wire rings
Moderate-high
20-30 lbs
Good
High (tedious)
Scale
Small plates on fabric
Moderate
25-35 lbs
Good
Moderate
Brigandine
Small plates riveted in fabric
High
20-30 lbs
Good
Moderate-high
Plate (partial)
Large steel plates
Very high
15-25 lbs
Moderate
High
Full plate harness
Articulated steel plates
Maximum
40-60 lbs
Moderate
Very high
Chapter 2: Plate Armor Basics
Materials: 1) Mild steel sheet: 18-20 gauge (0.040-0.048 inch) for most armor. 2) Medium carbon steel: 16-18 gauge for high-impact areas (breastplate). 3) Hardened steel: heat-treated for maximum protection (advanced). 4) Brass or copper: decorative elements, trim. 5) Leather: straps, padding attachment, articulation.
Armor Piece
Gauge
Coverage
Difficulty
Helmet (basic)
16-18 gauge
Head
Moderate-high
Breastplate
16-18 gauge
Chest
High
Backplate
18-20 gauge
Back
Moderate-high
Pauldrons (shoulders)
18-20 gauge
Shoulders
High (articulated)
Vambraces (forearms)
18-20 gauge
Forearms
Moderate
Greaves (shins)
18-20 gauge
Lower legs
Moderate
Gauntlets (hands)
20-22 gauge
Hands
Very high
Chapter 3: Plate Forming Techniques
Technique
Tool
Purpose
Application
Dishing
Ball stake + hammer
Create concave curves
Helmets, breastplates
Raising
Raising stake + hammer
Form deep shapes from flat
Helmets, cups
Planishing
Flat stake + planishing hammer
Smooth surface
All pieces
Fluting
Fluting stake + hammer
Create ridges (strength)
Breastplates, greaves
Edge rolling
Edge roller or hammer
Roll edges (safety, strength)
All edges
Riveting
Rivet set + hammer
Join pieces
All assembly
Dishing process: 1) Cut plate to pattern (add 1 inch margin). 2) Anneal plate (heat to dull red, air cool). 3) Place plate over dishing form (concave wood block or sandbag). 4) Strike with ball-peen hammer from center outward. 5) Work in concentric circles. 6) Anneal again when plate becomes work-hardened. 7) Repeat until desired depth is achieved. 8) Planish (smooth) on flat or curved stake.
Chapter 4: Articulation and Assembly
Joint Type
Method
Allows
Use
Rivet (fixed)
Permanent rivet
No movement
Fixed joints
Rivet (sliding)
Rivet in slot
Linear sliding
Lames (overlapping plates)
Rivet (pivot)
Rivet as pivot point
Rotation
Visors, arm joints
Leather hinge
Leather strip riveted to both plates
Bending
Gauntlets, sabatons
Buckle and strap
Leather strap with buckle
Adjustable closure
Attachment to body
Lacing
Cord through holes
Adjustable, flexible
Attachment, closure
Articulated pauldron (shoulder): 1) Cut 3-5 lames (overlapping plates) from pattern. 2) Dish each lame to match shoulder curve. 3) Overlap lames by 1/2-3/4 inch. 4) Drill rivet holes in overlap area. 5) Install sliding rivets (rivet in slot allows movement). 6) Each lame slides over the one below. 7) Assembly allows arm to raise and lower. 8) Attach to breastplate with leather straps.
Chapter 5: Padding and Fitting
Padding
Material
Thickness
Location
Purpose
Arming cap
Padded linen
1/2-1 inch
Under helmet
Comfort, shock absorption
Arming doublet
Quilted linen/wool
1/4-1/2 inch
Under all armor
Comfort, prevents chafing
Leather liner
Leather strips
1/8 inch
Inside helmet
Suspension, ventilation
Point ties
Linen cord
N/A
Arming doublet
Attach armor pieces
Reference Card
Anneal frequently (steel work-hardens as it is hammered; annealing (heating to dull red and air cooling) softens it for further forming; failing to anneal causes cracking). 2. Dish from center outward (when forming concave shapes, start hammering at the center and work outward in concentric circles; this prevents wrinkles and uneven thickness). 3. Articulation allows movement (overlapping plates connected with sliding rivets allow the armor to move with the body; without articulation, plate armor would be rigid and immobilizing). 4. Padding is essential (armor worn directly against the body causes bruising and chafing; a padded arming doublet absorbs shock and distributes the weight of the armor). 5. Weight distribution matters more than total weight (well-fitted armor distributes weight across the shoulders and hips; poorly fitted armor concentrates weight and causes fatigue). 6. Roll all edges (raw-cut steel edges are sharp and dangerous; rolling or turning edges prevents cuts and adds structural strength to the plate). 7. Fluting adds strength without weight (ridges pressed into flat plates dramatically increase stiffness; a fluted breastplate can be thinner and lighter than a smooth one of equal strength). 8. Armor making is the highest form of sheet metal work (forming complex three-dimensional shapes from flat steel, articulating them for movement, and fitting them to a human body requires mastery of every metalworking technique).
